Physical objects that are used to teach Musa are called manipulables.
Here's a fantastic resource: a box of Musa letter shapes you can make at home.
(Thanks to Logan Turner)
We've also made Musa tiles - these have an assortment of shapes designed for English. Here they are in a frame suitable for hanging.
To make your own, here are two image filea:
These images show which backs go with which fronts, but we cut the printouts before applying them, so it doesn't really matter. Print these images on sticky paper - your choice of color - and cut along the gray lines. We ordered 25mm (1 inch) tiles and blocks online, and we also ordered a 5mm rounded-corner cutter for the tiles.
Instead of trying to guess how much you'll need of each shape, just use the shapes you need, when you need them. We put each pair of tops and bottoms (one for orthogonal stems and the other for diagonal stems) on opposite sides of the same tile, and we put a blank on back of every vowel.
We also tried lasercutting them, but the contrast is much better with paper, and it's much cheaper and less complicated.
And here are some Musa Alphabet Blocks:
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